Battery Pack Front Member Cooling for HV Distribution Box Heat
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Solution Overview
Problem
Existing battery packs face challenges in thermal management, which affects efficiency, range, charging rate, and safety, particularly in electric vehicles.
Innovation Solution
A casted member within the battery pack enclosure integrates coolant pathways to cool the high voltage distribution box and other electrical components, facilitating efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional battery pack designs are used without integrated coolant pathways, then the structural simplicity is maintained, but thermal management efficiency deteriorates
Solution Approach 1:
The patent integrates coolant pathways directly into the casted front member structure, merging the structural component with the thermal management function. This eliminates the need for separate cooling plates or thermal management components, thereby improving thermal management efficiency while avoiding additional structural complexity
Solution Approach 2:
The casted front member serves multiple functions: it provides structural support for the battery pack enclosure and simultaneously acts as a thermal management component with integrated coolant pathways. This multi-functionality improves cooling efficiency without adding separate dedicated cooling structures
2Temperature
If coolant pathways are added to cool electrical components, then thermal management improves, but manufacturing complexity increases
Solution Approach 1:
The coolant pathways are integrated into the casting process of the front member, combining the structural manufacturing with the cooling channel formation. This allows both the structural component and thermal management function to be produced in a single casting operation, improving cooling effectiveness without significantly increasing manufacturing complexity
3Productivity
If fast charging is enabled with integrated cooling, then charging rate improves, but thermal management system complexity increases
Solution Approach 1:
The thermal management system is merged with the structural front member through integrated coolant pathways, enabling efficient heat removal during fast charging. This integration provides the necessary cooling capacity for high charging rates while avoiding the complexity of separate, dedicated cooling systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances thermal management, enabling fast charging, improved vehicle performance, and increased safety by effectively cooling critical components.
Implementation Method 1
one or more fluid channels within one or more walls of the casted member, the one or more fluid channels fluidly coupled to the opening
Implementation Method 2
providing the coolant into the one or more fluid channels to cool the high voltage distribution box disposed within a cavity in the casted member
Data Source
AI summary
Aspects of the disclosure relate to thermal management aspects of a battery pack. A casted front member of a battery pack enclosure may facilitate cooling of a high voltage distribution box (HVDB) within a cavity of the casted front member. Cooling of other electrical components, such as a busbar can also be provided. Cooling of the HVDB and/or other electrical components external to the battery modules and/or battery cells in a battery pack can facilitate fast charging, vehicle acceleration, component reliability, and/or other advantages.